Performance Spectrum

Caterpillar Motoren GmbH & Co. KGCaterpillar Motoren Rostock GmbHCaterpillar Castings Kiel GmbH

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Contents

1. CaterPillar Motoren GMbH & Co. KG in Kiel 1.1 Location and Transportation 1.2 Crane Capacity

2. MaCHineS 2.1 CNC-Milling Machines / Fastems 2.2 CNC-Lathe / Milling Machines / MillTurn 2.3 CNC-Lathe 2.4 CNC-Surface-/ Profile Grinding 2.5 Vertical Milling Machine 2.6 Portal Machining Center 2.7 3D-Measuring Machines (CMM)

3. rePair Center 4.1 REParts Center / Repair Center

4. MaterialS laboratory

5. MeaSurinG laboratory / MeaSurinG deviCeS

6. CaterPillar CaStinGS Kiel GMbH 3.1 Caterpillar Castings Profile 3.2 Caterpillar Castings Competencies

7. CaterPillar Motoren roStoCK GMbH 7.1 Engine Testbeds

8. ContaCtS

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1. CaterPillar Motoren GMbH & Co. KG in Kiel

Foundation• Acquisition of Krupp MaK Maschinenbau GmbH by Caterpillar Inc. in 1997 and foundation of Caterpillar Motoren GmbH & Co. KG.

today• Competence center of medium-speed engines.• Research, development and production of marine engines with trademark MaK and engines for power stations and oil industry with trademark CAT. • Headquarter of accounting, finance and human resources.• 6-Sigma project work• Caterpillar Motoren GmbH & Co. KG has a modern an highly adaptable machine park.• The key competence is the production of crankcases, con rods, cylinder heads, valve spindles.

1.1 loCation and tranSPortation

As Caterpillar Motoren GmbH & Co. KG is located in Kiel, it provides great logistical advantages for international customers through its accessibility to international traffic. Large cast parts can be embarked using the quay crane.

1.2 Crane CaPaCity

Handling• Crane in loading position in front of the hall.• Direct loading of truck/trailer; • Crane capacity: 200 t.

Shipping• Direct access to quay.• International harbor registration (ISPS-Code) Water depth: 6 m;• Crane capacity: 200 t.

areaProperty: Production Area: Office Space:

Caterpillar Motoren GmbH & Co. KG is continuously improving health, safety, environmental protection and quality standards according to management system norms DIN EN ISO 9001 , DIN EN ISO 14001 and OHSAS 18001.

200.000 m²68.200 m²25.500 m²

Caterpillar Motoren GmbH & Co. KG in Kiel

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Machines

2.1 CnC-MillinG MaCHineS / FaSteMS

Milling technology Control axistravel (mm) Machine

ManufacturerX-axis y-axis Z-axis

2 x BAZ; universal; rotary table; horizontal/vertical; 5 sided machining; 3D milling, aut. tool change

Siemens 840D 5 1600 1200 1700 Heller MCH-450

Interference area H: 1450 mm,Ø 1890 mmNC concentric table360° x 0,001Pallet size: 1000 x 800 mm

2 x BAZ; universal; rotary table; horizontal milling; aut. tool change

Fanuc 4 1350 1150 1150 Toyoda FH80

Interference area H: 1300 mm,Ø 1300 mmNC concentric table360° x 0,001Pallet size: 800 x 800 mm

1 x BAZ; universal; rotary table; horizontal milling; aut. tool change

Siemens 840D 4 1000 1000 1000 Heller H6000

Interference area H: 1290 mmØ 1200 mmNC concentric table360° x 0,001Pallet size: 800 x 630 mm

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2.2 CnC-latHe / MillinG MaCHine / Millturn

lathe / Milling technology Control axistravel (mm) Machine

ManufacturerX-axis y-axis Z-axis

1 x MillTurn; universal; lathe chuck; horizontal / vertical; 5 side machining; 3D milling, aut. tool change

Siemens 840D 5 720 600 3150 WFL 65

Distance between centers 3000 mm;circulation-Ø board 840 mm;slide 830 mm

3 x MillTurn; universal; lathe chuck; horizontal / vertical; 5 side machining; 3D milling; aut. tool change

Siemens 840D 5 920 650 3330 WFL 120

Distance between centers 3000 mm;circulation-Ø board 1220 mm; slide 1140 mm

2.3 CnC-latHe

lathe technology Control axis dimensions Machine manufacturer

One slide grinding;aut. tool change;modernized control

Siemens 840D 2 Clamping table: Max. building: Height face plate: max. lifting capacity face plate:

2000 mm2500 mm1500 mm

16 t

Schiess Kopp DE 200

Machines

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Machines

2.4 CnC-SurFaCe / ProFile GrindinG

Grinding technology Control axistravel (mm) Machine

ManufacturerX-axis y-axis Z-axis

Mägerle; universal;surface / profile grinding;flat table; horizontal

Siemens 840D 3 2600 900 750 MGC-L

Grinding wheel Ø 550 mm, B: 160 mmCircumference speed 35/50 m/s

Mägerle Siemens 840D 3 1950 620 613 MGC-L

Grinding wheel Ø 500 mm,B: 140 mm (geared)B: 120 mm (flat)Circumference speed 15/16 m/s

2.5 vertiCal MillinG MaCHine

Milling technology Control axistravel (mm) Machine

ManufacturerX-axis y-axis Z-axis

BAZ; universal vertical;milling machine; pendulum pallet mode; aut. tool change

Siemens 840D 3 2 x 2300 825 600 Unisign 6000

Table size L: 2500 x B: 1000 mmMax. lifting capacity: 1000 kg each table

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2.6 Portal MaCHininG Center

Portal Milling technology Control axistravel (mm) Machine

ManufacturerX-axis y-axis Z1-axis W-axis Z2-axisBAZ 1-2; universal vertical;5 side machining (diverse angle heads); aut. tool change;aut. pallet change;aut. angle head change;access to a Hinst-washing cabin

Siemens 840C 5 10000 +/- 2400 1500 3500 500 Waldrich Coburg PMC 4000Total length:

Total width:Passage height:Passage width:Pallet size:Max. lifting capacity:

24500 mm12500 mm

4500 mm4000 mm

9000 x 3000 mm100 t

BAZ 3; universal vertical;5 side machining (diverse angle heads); aut. tool change;aut. pallet change;aut. angle head change;access to a Hinst-washing cabin

Siemens 840D 5 13000 +/- 2750 1500 3500 500 Waldrich Coburg PowerTec 4500Total length:

Total width:Total height:Passage height:Passage width:Pallet size:Max. lifting capacity:

26000 mm2500 mm8500 mm4500 mm4500 mm

9000 x 3000 mm100 t

2.7 3d MeaSurinG MaCHine (CMM)

3d Measuring technology Control axistravel (mm) Machine

ManufacturerX-axis y-axis Z-axis

Accuracy with „VAST Gold“-scanning measuring headLength measuring deviation: MPE_E = (8,0 + L/200) µmMeasuring deviation: MPE_E = 5 µmScanning measuring deviation: MPE_THP = 5 µm; _TAU = 75 sSurge baffle system with 36 membrane air springs insulators; climate cabin 22°C at relative humidity 30-60% ± 10%

Calypso Zeiss

3 5000 11000 3500 Zeiss MMZ-G 50/110/35Total length:

Total width:Passage height:Pallet size:Max. lifting capacity:

11000 mm5000 mm3500 mm

10000 x 3000 mm80 t

Machines

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repair Center

3.1 rePartS Center / rePair Center

repair of engine Components according to Customer orders: • cylinder heads, connecting rods, vibration dampers, piston crowns, exhaust valve cages, injection pumps, turbochargers, liners, rocker arm/rocker arm brackets, starting valves, cooling water- and oil pumps, engine blocks, bedplates, cylinder frames, crankshafts, flywheels, flange shafts, joint rings, valve stems, governor drives, all further components upon request

reconditioning of MaK engine Components Within the Scope of the exchange Program:• cylinder heads, connecting rods, vibration dampers, piston crowns, exhaust valve cages, injection pumps, turbocharger cartridges, liners

inspection and assessment of used engine Components • regarding their further use or damage analysis.

assembly of assembly Groups: • crankshafts, camshafts, cylinder heads, nozzle holders, etc.

repair of Complete engines• in the workshop or on site

Worldwide dispatch of Service technicians • for repair jobs, supervision

Manufacture of Parts of any Kind: • according to Caterpillar Motoren quality standard based on customer drawings, technical sketches or models. Upon request, also a design drawing can be prepared.

General Machining and Manufacture:• turning, milling, ultra-fine and deep hole drilling, grinding, mill jobs, balancing, washing.

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4. MaterialS laboratory

Metallography• Scanning electron microscope (REM)• Micro analysis (EDX, only with REM)• Metallography• Optical microscopy und macroscopy, incl. photo documentation• Ambulant metallography• Digital photo documentation, incl. photo editing/-analysis

destructive Material testing• Tensile test without 0,2% limit• Tensile test with 0,2% limit• Hardness test Brinell/Vickers/Rockwell • Hardness test HV low load hardness tester• Hardness profile• Notch impact test at RT/-20°C/-40°C, 3 samples• Other material tests• Sample production

non-destructive Material testing• Ultrasonic analysis• Dye penetrant inspection• Magnetic particle testing

endoscopy• Analysis with flexible- and stiff endoscope

Chemistry• Spectral-block analysis: (Fe-,Al-,Cu-,Ni-,Co-based alloy)• Sample preparation

Service/Consulting• Simple test report/certificate• Detailed test report/engineering service• Technicians• Contact for classification societies

Materials laboratory

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Measuring laboratory / Measuring devices

5. MeaSurinG laboratory / MeaSurinG deviCeS

Components of all different sizes and up to 2 t weight can be measured in our measuring laboratories. For components of bigger dimensions we have europe‘s largest measuring machine of this kind from Zeiss at our disposal (for details please see 2.7 3D Measuring Machine (CMM)).

3d Measuring technology Control axisMeasuring range (mm) Machine

ManufacturerX-axis y-axis Z-axis

Universal measuring centerAccuracy with “VAST Gold“-scanning measuring head; rotary tableLength measuring deviationMPE_E = (2,9 +L/300) µm

Calypso 3 1200 2400 1000 Zeiss Prismo 10 12/24/10Pallet size: 800 x 1200 mm

Max. lifting capacity: 2 t

Universal measuring centerAccuracy with “VAST Gold“-scanning measuring head (modernized in 2012); rotary table with highly precise air-bedded bearingLength measuring deviation MPE_E = (2,8 +L/200) µm

Calypso 3 800 1200 600 Zeiss UMM 850 L

Max. capacity: 1 t

Form measuring device Roundpack 3 200 440 300 Mitutoyo RA-120P

Max. lifting capacity: 25 kg

Surface measuring device/roughness measuring device;MFW 250 µm

MarWin 3 Measuring range: 0-200 mm (x-Achse)Max. lifting capacity: 350 kg

Mahr MarSurf XCR200 ST 750

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Caterpillar Castings Kiel GmbH

6.1 CaterPillar CaStinGS ProFile

The location has more than 100 years of tradition and experience. Our products stand for remarkable quality, high durability and high level precision.

our service with 100 employees: Consulting

• Material consultancy• Design consultancy• Filling- and solidification simulation

Model Construction• Model planning / model construction

Moulding Process• Cold Box System• Furan resin system

Material• Grey cast iron (EN-GJL)• Cast iron with vermicular graphite (EN-GJV)• Spheroidal graphite cast (EN-GJS)

Capacity• 15000 tons/year capacity• 1 x 13 t + 2 x 3 t melting furnance• 60 t largest single piece capability

Certificates• DIN ISO 9001,• LR• GL• DNV• ABS• BV

Finishing treatment• Blasting/fettling• Heat treatment/melting• Painting/priming

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6.2 CaterPillar CaStinGS CoMPetenCieS

Melting Process• Material consulting/target recipe to meet customer requirements• In-process metallurgical analysis• Magnesium wire and inoculation treatment

Moulding Process• Sand regeneration• Cores production• Forms production• Logistics

Support Process• Tooling management• Simulation• Metallurgical analysis• Material certificates• Ultrasonic inspection• 3D layout

Fettling• 1 x Blastman automated blast cleaning system L: 7,8 m x B: 5,8 m x H: 5,0 m

Sand System• Furan resin/ Cold box sand system• Mechanical regeneration in house• Metal separation• Crushing• Cooling• Dust separation• Mixing with new sand• Thermal regeneration by external supplier

Sand laboratory• Fracture strength• Grain size• Humidity• Gas information

Pit / Moulding box• Flexible pits with variable compartments for large parts L: 22 m x B: 8 m x T: 4 m• Flasks for smaller parts

Painting• Max. dimensions: L: 7,0 m x B: 2,5 m x H: 2,7 m

Caterpillar Castings Kiel GmbH

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7.1 enGine teStbedS

testbedPower Speed rotation

Fuel remarkstestbed Size(l, W, H)

(kW) (rpm) (cw / ccw) (m)

#1 4.200

14.400

max. 3.000

max. 800

cw / ccw MDO / Gas Dyno L: 17,5T: 13,2H: 10,8

#2 10.000

18.850 max. 650 cw / ccw

MDO / Gas Loadbank

Dyno

690 V/3,3-13,8 kV

45-63 Hz

L: 20,8T: 13,8H: 11,4

#3 10.000

14.400 max. 800 cw / ccw

MDO / Gas Loadbank

Dyno

690 V/3,3-13,8 kV

45-63 Hz

L: 17,5T: 13,8H: 11,4

#4 10.000 max. 1.500 cw / ccw MDO / Gas Dyno L: 16,9T: 13,8H: 11,1

#5 12.000 MDO / Gas Loadbank 3,3-13,8 kV50-60 Hz

L: 16,9T: 13,2H: 10,8

#6 4.200

11.000

max. 3.000

max. 1.500

cw / ccw MDO / Gas / Gas mixture

Dyno L: 17,6T: 11,4H: 11,1

#7 4.200

11.000

max. 3.000

max. 1.500

cw / ccw MDO / Gas / Gas mixture / HFO

Dyno Exhaust gas treatment DeSOx & DeNox

L: 17,6T: 11,1H: 10,1

Caterpillar Motoren rostock GmbH

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notes

Subject to change without notice.Leaflet No. 109 · 08.16 · e · L+S · VM3LEBQ0002-01

© 2016 Caterpillar All Rights Reserved. Printed in Germany. CAT, CATERPILLAR, their respective logos, MaK, "Caterpillar Yellow" and the POWER EDGE trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.

Caterpillar Motoren GmbH & Co. KG

KielFalckensteiner Str. 224159 Kiel

Phone: +49 (0) 431/3995-0

Caterpillar Motoren rostock GmbH

RostockWerftallee 1318119 Rostock

Phone: +49 (0) 381/377 98-0

Caterpillar Castings Kiel GmbH

KielFalckensteiner Str. 224159 Kiel

Phone: +49 (0) 431/3995-0

Contacts

Hans-ulrich HölkManagementTelefon: +49 (0) 431 / 3995 3020Telefax: +49 (0) 431 / 3995 5020hoelk_ulrich@cat.com

Stephan denckerProject ManagerTelefon: +49 (0) 431 / 3995 2973Telefax: +49 (0) 431 / 3995 4973dencker_stephan@cat.com

Jens englerFactory Manager / ProductionTelefon: +49 (0) 431 / 3995 2441Telefax: +49 (0) 431 / 3995 4441engler_jens@cat.com

roman PlaggeFactory Manager / RostockPhone: +49 (0) 381 / 3779 8112plagge_roman@cat.com

Frank SeidelManager Pattern / FoundryTelefon: +49 (0) 431 / 3995 2323Telefax: +49 (0) 431 / 3995 4323seidel_frank@cat.com